Edge roll for mattress spring structures



Nov. 22, 1955 w. F. RICHARDSON 2,724,330

EDGE ROLL FOR MATTRESS SPRING STRUCTURES Filed Feb. 9, 1953 2 Sheets-Sheet l BY i (f u NOV- 22, 1955 w. F. RICHARDSON EDGE ROLL FOR MATTRESS SPRING STRUCTURES 2 Sheets-Sheet 2 Filed Feb. 9, 1953 ,Y AA

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United States Patent Office 2,724,130 Patented Nov. 22, 1955 EDGE ROLL FR MATTRESS SPRING STRUCTURES William F. Richardson, Carthage, Mo., assigner to Flex- O-Lators, Ine., Carthage, Mo., a corporation of Mxssouri Application February 9, 1953, Serial No. 335,706

9 Claims. (Cl. 5--360) This invention relates `to new and useful `improvements in edge rolls for mattress spring structures, and particularly to an edge roll which is padded and adapted to be applied to the marginal edges of a coil spring assembly such as is used in spring mattresses and the like, whereby to pro.ect the upholstery or padding layers which are applied over the springs against friction and wear by the springs, and to provide greater comfort for the user.

The principal object of the present invention is the` provision of an edge roll of the character described having novel means for attaching it to a spring assembly, it being a self-clamping edge roll attachable to a spring structure by the action of a spring member built into the edge roll itself.

Another object is the provision, in an edge roll of the character described having an internal spring which serves not only to attach the edge roll to a mattress spring assembly, but also serves as the structural base and forming nrears for the edge roll.

r 1er obiects are simplicity and economy of construction, ease and convenience of application, and efficiency and dependability of operation.

With these objects in View, as well as other objects which will appear in the course of the speciication, reference will be had tothe drawing, wherein:

Fig. 1 is a fragmentary plan view of a spring assembly such as is commonly used in mattresses, seating cushions, and the like, with an edge roll embodying "the present invention applied thereto.

Fig. 2 is an enlarged fragmentary sectional view taken on line Il-Il of Fig. l.

Fig. 3 is an enlarged plan view of a section of the edge roll, with the various layers thereof broken away to illustrate the construction thereof.

Fig. 4 is an inner edge elevational view of the spring wire core of the edge roll shown in Fig. 3.

Fig. 5 is a sectional view taken on line V-V of Fig. 4.

Fig. 6 is a plan View of a slightly modiiied form of the spring Wire core used in the edge roll.

Fig. `7 is an inner edge elevational view of the spring wire core shown in Fig. 6. j

Fig. 8 is a sectional view taken line VlH-Vlll of Fig. 7.

Like reference numerals apply to similar parts throughout the several views, and the numeral 2 applies to a mattress or cushion spring assembly comprising a plurality of spool-shaped helical springs 4 arranged in parallel, spaced-apart rows with their axes substantially parallel. .Each of said springs has a substantially circular top loop 6 and bottom loop 3, said top and bottom loops lying respectively in planes forming the upper and lower faces of the assembly. The top loops of adjacent springs in each row of springs overlap slightlyand are joined by a plurality of helical binder coils 10 which extend across the upper face of the assembly transversely to the rows of springs, and which extend between corresponding pairs of` springs in each row ofsprings,'ceiling-about the-overlapping portions of the toploopsf-therieot.--l3ottern` loops 8 of the springs may be similarly joined by helical binder coils. Extending around the marginal edge of the top face of the asssembly is a margin wire 12, about which is disposed a helical binder coil 14, said binder coil joining saidmargin wire to the adjacent portions of the top loops 6 of the springs. The bottom face of the spring assembly is similarly provided with a margin wire 16 and helical binder coil 1S. lt is to be understood, however', that the arrangement of springs 4, and the particular means for assembling them, are not essential features of the present invention, which relates only to an edge roll for padding and protecting the marginal edges of the spring assembly.

The edge roll 20, which forms the subject matter of this invention, includes, as best shownin Figs. 3, 4 and 5,

`a continuous length of spring wire 22 formed to present a continuous series of loops, said loops being successively olfset in a direction longitudinal to the edge roll. Said loops are designated alternately by the numerals 24 and 26, and are generally circular. Said wire forms the core or foundation of the edge roll. It will be noted, as best shown in Figs. 4 and 5, that loops 24 are offset from loops 26 transversely of the edge roll, whereby the wire 22 forms, in skeleton form, a generally channel-shaped member, loops 24 forming one flange or wall of the channel, loops 26 forming the other flange or wall of the channel, and the portions 28 of the wire joining the loops forming the base or web of the channel. Said channel is generally C-shaped in cross-section, as best shown in Fig. 5. Wire 22 is tensioned so as to urge loops 24 and 26 toward each other, so as to close the channel. It will be noted that each loop 24 overlaps the two adjacent loops 26 longitudinally of the channel, whereby loops 24 cannot pass between loops 26, and whereby each loop 24 has a contact area with each of said loops 26.

The channel formed by wire 22 is covered, as best shown in Figs. 2 and 3, with a suitably padding material, both the inner and outer surfaces of said channel being covered. Said padding is illustrated as formed of continuous strips of `sheet padding extending longitudinally of the channel, two sheets 30 being disposed on the outer side of the channel and a single sheet 32 being disposed on the inside of the channel. Said padding sheets may be of any suitable material. A soft, thick, pulp paper, as illustratedhas been found satisfactory and economical, but other materials such as felt, cotton, or fiber could be used. Also, the paper could be of the form known as wailled or dimpled, having indentations or irregularities formed in the surface thereof, and in this form would have a greater degree of yieldability.

A cover sheet. 34 is wrapped about the padding layers, covering both the inside and outside of the channel, to retain the padding material firmly in place. Said cover sheet should be pliable to provide flexibility of the edge roll, and yet possess the requisite structural strength. An X-crepe paper has been found satisfactory and economical, but other materials such as fabric could be used. Said cover sheet is in the form of a strip extending longitudinally of the edge roll. The longitudinal edge portions of said cover sheet overlap as at 36, and can be joined as with adhesive orstitching, or as shown can be arranged so that the overlapping edge portions lie within the channel formed by wire v22, so the edge portions will be clampingly retained by the spring action of the channel.

In use, the walls of the edge roll, which has the form of a channel padded both inside and out, and with the walls thereof urged resiliently together, are spread apart and fitted around the top loops 6 of springs 4, as best shown in Fig. 2, the portions of said top loops at the margin of the spring assembly tting into said edge roll. rl`he walls of the edge roll are then released, whereupon they clamp the .toploops `6 of springs 4, 'andlalsohelical binder coil 14, therebetween to hold the edge roll firmly in place against accidental dislodgement from the springs. A suitable tool for spreading apart the walls of the edge roll preparatory to applying it to the mattress springs -has been developed, but forms no part of the present invention. Another edge roll may be similarly applied to the bottom loops 8 of the springs 4 if desired. It is obvious,

however, that only the top edge roll will be used where, as in many types of seating cushions, the bottoms of springs 4 are attached to a rigid base. Theupholstery padding, not shown, may then be applied over the spring assembly and edge roll in any suitable manner. The function of the edge roll in preventing wearing and eventual penetration of the upholstery by the springs, and in providing a more comfortable mattress or cushion, is well known.

Thus it is apparent that an edge roll having several advantages has been produced. The particular formation of the spring wire core 22 provides an edge roll which is uncommonly flexible, whereby said edge roll may be easily lead around corners of the spring assembly, as

shown in Fig. l, and whereby the edge roll will deform and flex easily when a load is applied to the spring assembly when in use. Also, the fact that the clamping action between the loops 24 and 26 is not continuous along the length of the edge roll, but may be regarded as provided by a series of more-or-less independent clamps, provides that it will clamp firmly on the spring assembly despite variations of the thickness of the parts clamped. For example, were the relatively thick helical binder coils 10 to extend sufficiently near the margin of the assembly to extend between the walls of the edge roll, the edge roll would clamp firmly thereon, and would nonetheless also clamp firmly on adjacent portions of the relatively thin spring loops 6.

The padding layer 32 on the inside of the edge roll channel prevents any grinding, rubbing, or rattling noises of wire 22 against the spring assembly. It will be noted also that the wide open C-shape of the edge roll channel permits it to be placed over the marginal binder coil 14. It is obvious however, that if the spring assembly did not have marginal coils 14, the edge roll channel could be much flatter, with the loops 24 and 26 relatively much closer together, and that generally the cross-sectional shape of the edge roll channel could be made in any configuration desirable to conform to the particular spring assembly to which it is to be applied.

Figs. 6, 7 and 8 show a modified form of spring wire core corresponding to wire 22 in Figs. 2 to 5. It comprises a length of spring wire 38 formed to present a series of loops designated alternately by the numerals 40 and 42 and lying in generally parallel planes so that loops 40 define one wall of a channel, loops 42 form the other wall of a channel, and the portions 44 of the wire joining the loops form the base or web of the channel. The loops overlap longitudinally of the channel, and loops 40 are urged resiliently toward loops 42, as in wire 22. Instead of being generally circular, however, the loops are formed generally as isosceles triangles, with the reach of wire forming the base 46 of each triangle lying in a line extending longitudinally of the channel. Padding `3:0*32 and the cover sheet 34 may be applied thereto in the same manner as to wire 22 in Fig. 3. This modification operates in substantially the same manner as the edge roll in Figs. 2 to 5, except that straight wire reaches 46 provide an improved straight-line clamping action along thek open edge of the edge roll channel.

While I have shown and described certain specific embodiments of my invention, it is apparent that many minor changes of structure and operation could be made without departing from the spirit f the invention as defined by the scope of the appended claims.

What I claim as new and desire to protect by Letters Patent is: n

1. An edge roll for mattress spring structures comprising a continuous strand of resilient material formed to define a skeletonized, generally channel-shaped member, said strand being tensioned whereby the portions thereof forming the respective opposite walls of said channel member are urged resiliently toward each other, and a layer of padding material attached to said channelshaped member and covering the external surface thereof.

2. An edge roll for mattress spring structures comprising a continuous strand of resilient material formed to define a skeletonized, generally channel-shaped member, said strand being tensioned whereby the portions thereof forming the respective opposite walls of said channel member are urged resiliently toward each other, and a layer of padding material attached to said channel-shaped member and covering both the internal and external surfaces thereof.

3. An edge roll for mattress spring structures comprising a continuous strand of resilient material formed to define a skeletonized, generally channel-shaped member, said strand being tensioned whereby the opposite walls of said channel member are urged resiliently toward each other, a layer of padding material covering both the internal and external surfaces of said channel-shaped member, and a cover sheet of pliable material covering said padding material.

4. An edge roll for mattress spring structures comprising a continuous strand of resilient material formed to define a skeletonized, generally channel-shaped member, said strand being tensioned whereby the opposite walls of said channel member are urged resiliently toward each other, a layer of padding material covering both the internal and external surfaces of said channel member, and a cover sheet of pliable material covering said padding material, said cover sheet extending longitudinally of said channel member with the longitudinal edge portions thereof disposed between the opposing walls of said channel member, whereby to be retained by the clamping action of said walls.

5. An edge roll for mattress spring structures comprising a continuous strand of resilient material formed to present a series of loops lying alternately in a pair of generally parallel planes and successively offset from each other in a direction parallel to the planes of said loops whereby to define a skeletonized channel, said loops alternately lying in and forming the opposing walls of said channel and the portions of said strand joining said loops lying in and forming the base of said channel, said strand being tensioned whereby the loops forming each of said channel walls are resiliently urged toward the loops forming the opposite channel wall, and a layer of padding material covering and attached to the outer surface of the channel formed by said strand.

6. An edge roll for mattress spring structures comprising a continuous strand of resilient wire formed to present a series of loops lying alternately in a pair of generally parallel planes and successively offset from each other in a direction parallel to the planes of said loops whereby t0 form a skeletonized channel, said loops lying alternately in and defining the opposing walls of said channel, and the portions of said wire joining the loops lying in and forming the base of said channel, each of said loops overlapping the two adjacent loops in the opposing channel wall in a direction longitudinal to said channel, said wire being tensioned whereby the opposing walls of said channel are urged resiliently toward each other, and a layer of padding material applied over the external and internal surfaces of said channel.

7. An edge roll for mattress spring structures comprising a continuous strand of resilient wire formed to present a series of loops lying alternately in a pair of generally parallel planes and successively offset from each other in a direction parallel to the planes of said loops whereby -to form a skeletonized channel, said loops lying alternately in and defining the opposing walls of said channel,

and the portions of said wire joining the loops lying in and forming the base of said channel, the loops forming each of said channel walls being disposed in spaced apart relation with each of said loops overlapping the two adjacent loops in the opposing channel wall in a direction longitudinal to said channel, said wire being tensioned whereby the opposnig walls of said channel are urged resiliently toward each other, and a layer of padding material applied over the external and internal surfaces of said channel.

8. An edge roll for mattress spring structures comprising a continuous strand of resilient wire formed to present a series of loops lying alternately in a pair of generally parallel planes and successively offset from each other in a direction parallel to the planes of said loops whereby to form a skeletonized channel, said loops being generally circular in form and lying alternately in and defining the opposing walls of said channel, and the portions of said wire joining the loops lying in and forming the base of said channel, each of said loops overlapping the two adjacent loops in the opposing channel wall in a direction longitudinal to said channel, said Wire being tensoned whereby the opposing walls of said channel are urged resiliently toward each other, and a layer of padding material applied over the external and internal surfaces of said channel.

9. An edge roll for mattress spring; structures con1- prising a continuous strand of resilient wire formed to present av series of loops lying alternately in a pair of generally parallel planes and successively offset from each other in a direction parallel to the planes of said loops whereby to form a skeletonized channel, said loops lying alternately in and defining the opposing walls of said channel, and the portions of said wire joining the loops lying in and forming the base of said channel, said loops each being generally triangular in form and including a generally straight reach of wire extending longitudinally of said channel at the open edge thereof, each of said loops overlapping the two adjacent loops in the opposing channel wall in a direction longitudinal to said channel, said wire being tensioned whereby the opposing Walls of said channel are urged resiliently toward each other, and a layer of padding material applied over the external and internal surfaces of said channel.

References Cited in the le of this patent UNITED STATES PATENTS 1,862,517 Schlegel June 7, 1932 1,955,187 Howard Apr. 17, 1934 2,004,364 Best June 11, 1935 

